WO2009123363A1

WO2009123363A1 - Method for manufacturing a film-shaped catalyst

Info

Publication number: WO2009123363A1
Application number: PCT/JP2009/057298
Authority: WO
Inventors: 松井邦夫; 佐藤雅安; 山下好美
Original assignee: 花王株式会社
Priority date: 2008-04-04
Filing date: 2009-04-03
Publication date: 2009-10-08
Also published as: CN101990465B; US20110065569A1; EP2260941A1; JP5449823B2; EP2260941B1; CN101990465A; EP2260941A4; ES2605238T3; JP2009262145A; US8501665B2

Abstract

Provided is a method for manufacturing a film-shaped catalyst, which involves: a process in which the film-shaped catalyst is manufactured by forming a catalyst layer on one or both surfaces of a support; a process in which the film-shaped catalyst is bent; and a process in which the film-shaped catalyst is cut as necessary. In the bending process, two gears are used as bending tools, said gears arranged to face one another so as to mesh, and bending is performed with a protective layer having a compression ratio of 40 to 95% placed in between the catalyst layer of the film-shaped catalyst and the two gears.

Description

Specification

Method for producing film catalyst

TECHNICAL FIELD The present invention relates to a method for producing a film catalyst suitable as a catalyst for gas-liquid reaction. BACKGROUND ART A film catalyst in which a catalyst is supported on a film substrate is known (WO 2 0 0 5/0 3 5 1 2 2). In order to increase the surface area, this film-like catalyst is sometimes processed and formed into a honeycomb shape in the form of a corrugation. During the forming process, the catalyst layer carried on the base material is wrinkled by contact with the forming tool. There is a problem that it may occur or, in some cases, the catalyst may fall off partially.

In JP-A 8-1 4 1 3 9 3, a metal base material having a catalyst layer was sandwiched between flexible plate-like members, and then passed between a pair of synthetic resin gears to form a corrugated shape. Thereafter, a method of heating a metal substrate is described, and it is described that a catalyst body is processed by sandwiching a high-quality paper as a flexible plate-like member with a polyethylene resin. When such a plate-shaped member is used, the stress acting on the catalyst layer cannot be sufficiently relaxed in the meshing space between the gears, and the catalyst layer may be damaged. Further, in the space for meshing between the gears, the pressure applied to the catalyst layer and the plate-like member increases, so that stress is applied to the synthetic resin gear and the durability of the gear is impaired. Also travel If wrinkles occur in the plate-like member at times, the total thickness of the plate-like member substantially increases at the wrinkled portion, so a very large stress is applied to the catalyst layer, and mechanical destruction of the catalyst layer cannot be avoided. Many issues existed.

JP-A 2000-1 898 14 describes a method of press molding with a molding apparatus using a mold for thermoforming a catalyst coated body in which a catalyst component is coated on an inorganic fiber or a net-like body. A molding apparatus is described in which a flexible porous layer is provided on the surface of a mold.

SUMMARY OF THE INVENTION The present invention comprises a step of forming a catalyst layer on one or both sides of a support to produce a film-like catalyst, and a step of bending the film-like catalyst. In the bending process, as the bending tool, two gears disposed so as to face each other are used as a bending tool, and between the catalyst layer of the film catalyst and the two gears. This is a method for producing a film-like catalyst, in which bending processing is performed with a protective material having a compression ratio of 40 to 95% interposed therebetween. In the present invention, the ratio (t ₂ ti) of the thickness of the film-like catalyst (t and the total thickness (t ₂ ) of the protective material is 4 to 20; And the relationship between t ₂ and t ₂ is t, <T <tt ₂ where T is a combination of the gears of the two gears. The distance between the gears, with the distance close to the shortest distance as the zero reference. The present invention comprises a step of forming a catalyst layer on one or both sides of a support to produce a film-like catalyst, and a step of pressing and bending the film-like catalyst. The bending tool includes two upper and lower plate-shaped bending tools, and the two plate-shaped bending tools have corrugated teeth on a flat plate, The concave and convex portions of the corrugated teeth are arranged so as to overlap with each other. When the upper plate and the lower plate are pressed with the two plate-shaped bending tools, the catalyst layer of the film catalyst and the bent portion are bent. This is a method for producing a film-like catalyst, which is bent in a state where a protective material having a compression ratio of 40 to 95% is interposed between the processing tool and the processing tool. Detailed Description of the Invention

JP—A 2 0 0 0— 1 8 9 8 1 4 suppresses the wear of the mold metal itself. In this way, the surface porous layer provided on the mold should have strength and durability. It was difficult. When stress is applied to the mold and the porous layer during molding, stress is concentrated at the interface, causing separation between the porous layer and the mold. Therefore, it was difficult to fix it permanently, that is, it was difficult to have durability in molding use. In addition, when a material such as acrylic rubber is used for the porous layer, the porous layer has a high friction coefficient, which causes problems such as damage to the catalyst body due to the frictional force applied to the catalyst body. The present invention provides a method for producing a film catalyst that can be processed into a desired shape without damaging the catalyst layer. According to the production method of the present invention, a film catalyst processed into a desired shape can be obtained without damaging the catalyst layer. The method for producing a film catalyst of the present invention is used as a catalyst for various organic synthesis reactions. It can be used as a method for producing a film catalyst. In the present invention, the protective material preferably has a dynamic friction coefficient of 0.05 to 0.25, or the protective material is a nonwoven fabric.

(1) First manufacturing method

<Manufacturing Process for Long Film Catalyst> First, in the first process, a catalyst layer is formed on one surface or both surfaces of a long support to manufacture a long film catalyst. The first production method is suitable for processing a long film-shaped catalyst, but can also be applied to processing a film-shaped catalyst of each desired shape.

(Preparation process of coating composition) The coating composition used for the production of a long film catalyst can be prepared as follows. As the powdered catalyst contained in the coating composition, a catalyst active material or a catalyst in which a catalyst active material is supported on a porous material can be used. The catalyst active material may be any component that is effective for the applied chemical reaction,

Ag, Au, Cu, Ni, Fe. AK Metal elements such as 4th period transition metal element, platinum group element, 3A group element of periodic table, Al force metal, Al force earth metal, etc. A metal oxide etc. can be mentioned. The porous material is a catalyst carrier that supports the catalytic active material. Examples of the porous material include activated carbon, alumina, silica, zeolite, titania, silica-alumina, and diatomaceous earth. Can be preferably used. Than Preferably, a porous material having a high surface area can be used, and a molecular sieve or the like can also be used. As a method for supporting the catalyst active material on the catalyst carrier, known methods such as a normal impregnation method, a co-impregnation method, a co-precipitation method, and an ion exchange method can be applied. The powdered catalyst preferably has an average particle size of 0.001 to 500 / zm, more preferably 0.5 to 150 mm, and even more preferably 1 to 50 m. A sharp distribution is preferred. Furthermore, the specific surface area by BET method is preferably 1 to 500 m ² / g, more preferably 5 to 200 mVg, and still more preferably 10 to 100 m ² / g. The content of the powdered catalyst in the solid content (100% by mass) in the coating composition is preferably 60 to 90% by mass, more preferably 60 to 85% by mass, and still more preferably 70 to 90% by mass. 8 5% by mass. The binder used in the coating composition is preferably one that is excellent in binding properties between the powdered catalysts and the support surface, withstands the reaction environment, and does not adversely affect the reaction system. Examples of such binders include cellulose resins such as carboxymethylcellulose hydroxyethyl cellulose, fluorine resins such as polytetrafluoroethylene and polyvinylidene fluoride, polyvinyl alcohol, urethane resins, epoxy resins, polyamide resins, and polyimides. Various thermoplastic resins and thermosetting resins such as resins, polyamide-imide resins, polyester resins, phenol resins, melamine resins, and silicone resins are used. By introducing a crosslinking reaction with a curing agent into these synthetic resins, Those that can be polymerized can also be used. Of these, thermosetting resins such as phenolic resin, furan resin, and epoxy resin are preferable, and more preferable at the time of curing. A thermosetting resin accompanied by a condensation reaction can be used. When a thermosetting resin is used as the binder, the strength of the coating film and the binding property are improved by improving the crosslinking density by the curing reaction, and the catalytic activity of the powdered catalyst is increased by making the catalyst coating film porous by the condensation reaction. It can be pulled out effectively. As an example of a preferred combination of a powdered catalyst and a binder, when the film-like catalyst obtained by the production method of this step is used in a reaction for producing a tertiary amine from alcohol and primary amine or secondary amine, A combination of monoruthenium ternary powder catalyst and phenol resin can be mentioned. The binder content in the solid content (100% by mass) in the coating composition is preferably 10 to 40% by mass, more preferably 15 to 40% by mass, and still more preferably 15 to 30% by mass. By making the content ratio of the powdered catalyst and the binder within the predetermined range, it becomes possible to control the degree of exposure of the powdered catalyst, and further, the catalytic activity ability inherent in the powdered catalyst is increased. It can be pulled out and the catalyst layer can be removed easily. When the content of the binder 1 in the solid content is 40% by mass or less, the thickness of the binder covering the surface of the powder catalyst or the coverage by the binder becomes appropriate, and the catalytic activity of the powder catalyst is sufficient. As a result, high catalytic activity can be exhibited. When the blending ratio of the binder in the solid content is 10% by mass or more, the catalytic activity is sufficiently developed, and the binding force between the powder catalysts or between the powder catalyst supports is improved, and the film catalyst. The amount of catalyst layer separation and partial dropout during the manufacturing process and reaction operation is suppressed In the coating composition, in addition to the powdered catalyst and binder, a solvent is used to improve the wettability of the powdered catalyst surface, dissolve the binder, and promote mixing and homogenization of these blends. Any solvent may be used as long as it does not adversely affect the catalytic activity of the powdered catalyst, and various water-soluble or water-insoluble solvents can be selected depending on the type of binder used. The pore structure of the film-like catalyst can be controlled by selecting one of these. The solvent preferably has good binder solubility, and may be used in combination of two or more solvents, and the pore structure of the catalyst layer can be changed by selecting a solvent suitable for the binder used. Can be controlled. Solvents include water; alcohols such as methyl alcohol, ethyl alcohol, isopropyl alcohol, butyl alcohol, and aryl alcohol; ketones such as acetone, methyl ethyl ketone (MEK), and methyl isobutyl ketone (MIBK); Diols or derivatives thereof such as monol, propylene glycol, diethylene glycol, polyethylene glycol, polypropylene glycol, diethylene glycol monoethyl ether, polypropylene glycol monoethyl ether, polyethylene glycol monoallyl ether, polypropylene glycol monoallyl ether; Glycerol or its derivatives such as glycerol monoethyl ether, glyceryl monoallyl ether; Ethers such as lofuran and dioxane; liquid paraffin, decane, decene, methylnaphthalene, decalin, kerosene, diphenylmethane, toluene, dimethylbenzene, ethylbenzene, jetylbenzene, propylbenzene, cyclohexane, partially hydrogenated Hydrocarbons such as triphenyl, polydimethylsiloxane, partially octyl-substituted polydimethylsiloxane, partially phenyl-substituted polydimethylsiloxane Silicone oils such as xanthone and fluorosilicone oil, halogenated hydrocarbons such as black benzene, dichlorobenzene, bromobenzene, chlorodiphenyl, and chlorodiphenyl benzene, Dailroll (manufactured by Daikin Industries, Ltd.), demnum ( Daikin Kogyo Co., Ltd.), etc., benzoyl ethyl benzoate, octyl benzoate, dioctyl benzoate, trioctyl trimellate, dibutyl sebacate, (meth) ethyl acrylate, (meth) butyl acrylate (Meiyu) Examples include ester compounds such as dodecyl acrylate, dimethylformamide, N-methyl-pyrrolidone, acetonitrile, and ethyl acetate. In addition to the above-mentioned components, the coating composition may contain a surfactant or a cutting agent as a dispersion aid, an inorganic particle, a fibrous material, etc. as an aggregate, and a high boiling point solvent as a porosity aid. it can. The coupling agent has an effect of improving physical properties by performing molecular crosslinking at the interface between the inorganic filler and the organic polymer matrix. As coupling agents, those commonly known as silane coupling agents, titanate coupling agents and aluminate coupling agents can be used, and a combination of multiple force coupling agents may be used to adjust the concentration. It may be used after diluting with a compatible organic solvent. As the fibrous substance, organic fiber or inorganic fiber is used. Examples of organic fibers include polyamide nylon 6, nylon 6 nylon fiber, polypinyl alcohol fiber, polyester polyethylene terephthalate, polybutylene terephthalate fiber, polyarylate fiber, polyvinylidene chloride, poly Examples thereof include vinyl chloride-based, polyacrylonitrile-based, and polyolefin-based polyethylene and polypropylene fibers. The organic fibers include organic regenerated fibers, and examples thereof include cellulose-based rayon and acetate. As inorganic fiber, Glass fiber, carbon fiber, activated carbon fiber, ceramic fiber, etc. can be used. By blending each of the fibers, the mechanical strength of the catalyst layer can be improved due to the manifestation of the aggregate effect. The preparation of the coating composition is not particularly limited as long as each component can be uniformly mixed, but in the present invention, it is preferably prepared using a media type mill or a pent shaker. By using a media-type mill, it is possible to uniformly treat each component of the coating composition described above from its structure and mechanism. Therefore, by controlling the particle size and dispersion state of the powdered catalyst, It is suitable for controlling the pore size distribution of the catalyst layer of the film catalyst. As media type mills, ball mills, trials, AD mills, twin AD mills, basket mills, twin basket mills, handy mills, daren mills, dynomils, apex mills, suyuichi mills, pisco mills, sand grinders and beads were used. You can list paint cheers. In the present invention, a dissolver-type mixing and dispersing machine can be used as a dispersing machine other than the media type mill. The solid content in the coating composition is preferably 10 to 80% by mass because the pore structure is controlled at the time of desorption of the solvent from the formed catalyst layer and affects the formation of the pore structure. More preferably, it is 20-70 mass%, More preferably, it is 25-65 mass%. The viscosity of the coating composition is selected within a preferable range depending on the coating method, and is, for example, 5 to 10,000 mPas, preferably 20 to 5000 mPas, more preferably 50 to l OOOmPas.

(Production of film catalyst) The coating composition is applied to a long support and formed into a film to produce a catalyst intermediate. Then, it can be dried (cured) at room temperature. As the coating method, conventionally known methods can be used, and various coating methods such as blade, roll, knife, bar, spray, dip, spin, comma, kiss, gravure, and die coating can be exemplified. Here, the formation of the magnetic layer on the support can be performed by using PDV, CVD, etc. in addition to coating. The film-like catalyst preferably has a catalyst layer thickness of 500 m or less, more preferably 100 Aim or less, and even more preferably 50 in or less. Also, catalyst loading per unit area, 0. 5~ 1 0 0 g Zni 2 is preferred,. 1 to 6 0 g Roh m ^2, more preferably, 1 0~ 3 0 g Zm ² is more preferred. The support used in the present invention is long or sheet-like, and the length and width are not particularly limited, and the thickness is preferably 1 mm or less. Examples of the material include copper foil, stainless steel foil, and aluminum foil. Preferably, copper foil and stainless steel foil can be used from the viewpoint of workability and corrosion resistance. Furthermore, the surface of the support is preferably subjected to a roughening treatment or a force pulling treatment from the viewpoint of improving the adhesion to the catalyst layer. For this force coupling treatment, the coupling agent described above can be used, and preferably the same kind as that used for preparing the paint can be used. The drying and curing processes are intended to remove the solvent and unreacted monomers contained in the coating composition after coating and film formation on the support. In addition to the case where the curing reaction proceeds with the drying, the heating temperature and the heating time are adjusted according to the composition of the coating composition. The curing reaction can also be allowed to proceed. The drying and curing process is preferably performed in an atmosphere heated with an inert gas such as air, water vapor, nitrogen, argon, or the like, or a method of spraying such a heat medium is used. In addition, radiant heat such as infrared rays or far infrared rays is used. Various methods such as a method of heating, a heating method using an induced conductive current by electromagnetic waves can be used, a method combining these methods, or a method of natural drying at room temperature (air drying) can also be used. Components desorbed in this step are a volatile component mainly composed of a solvent and a hardening reaction product. The volatile components other than the solvent include unreacted monomer components. The drying and curing conditions must be adjusted according to the physical properties of the volatile components, mainly the binder and solvent contained in the coating composition. The catalyst layer can be selected by selecting the solvent and setting the drying and curing conditions. The porous structure (pore volume) can be controlled. In the heat treatment with hot air, it is considered that the higher the drying temperature and the larger the amount of dry air, the faster the components are desorbed from the catalyst layer and the larger the pore structure (pore size, capacity). In addition, it is considered that the pore structure becomes smaller as the drying temperature is lower and the drying air volume is smaller. In addition to the elimination of volatile components, mainly solvents, from the coating composition, the formation of a crosslinked structure (network structure) formed by the progress of the curing / crosslinking reaction, and if there is a further condensation reaction, The pore structure is determined during the desorption stage. The drying and curing treatment employs a drying method and drying conditions that do not adversely affect the catalytic activity inherent in the powdered catalyst used in the present invention. In the present invention, a hot air drying process is used to obtain the desired film catalyst. The typical drying and curing conditions are 60 to 400, preferably 70 to 25, more preferably 80 to: at a temperature of L 50, preferably 0.5 to 3 O mZ. It is desirable to carry out the drying and curing treatment at a wind speed of sec, more preferably 1 to 2 O mZ sec, preferably 1 second or more, more preferably 10 minutes or more, and even more preferably 30 minutes or more. In the case where only drying without a curing reaction is intended, it is preferable to dry the coating composition immediately after applying the coating composition to the support. By adjusting the drying conditions at this time, the porosity of the coating film You can control the structure. Therefore, it is desirable that the time from the formation of the catalyst layer on the support to the elimination of the volatile components mainly composed of the solvent is shorter, preferably within 2 hours, more preferably within 30 minutes, and further. Preferably within 5 minutes. In the present invention, when the binder contains a thermosetting resin, the catalyst intermediate is shaped with the uncured product remaining in the catalyst layer obtained by coating and drying (prepolymer state), and then finally heated. It is desirable to process. The drying and curing treatment of the catalyst intermediate performed before the final heat treatment may be terminated in a state where an uncured product remains in the thermosetting resin. It is partly cured until handling at the time of shape processing can be performed, and it is desirable that the retention and mechanical strength of the catalyst layer be improved compared to the time of film formation. May remain in the order of. The drying before the final heat treatment for obtaining the target film-like catalyst is typically from 60 to 400, preferably from 70 to 25, more preferably, by hot air drying. 80-: at a temperature of L 50, preferably more than 0.5-3 O m / se It is desirable to perform the drying treatment at a wind speed of 1 to 2 O mZ sec, preferably for 0.5 to 300 seconds, more preferably for 1 to 100 seconds. Step of bending a long film catalyst> Next, this step will be described with reference to FIG. FIG. 1 is a conceptual diagram for explaining this process. A long film catalyst 10 produced in the previous process is wound on the delivery roll 1 and is sequentially delivered in the direction of the arrow from the delivery roll 1. A catalyst layer is formed on one or both sides of the long film catalyst 10. The protective rolls 11 are wound around the delivery rolls 2 and 3, and are sent out in parallel with the delivery of the long film catalyst 10 from the delivery roll 1. The protective material 11 may be one sheet, but may be two or more layers. When two or more sheets are stacked, slip occurs between the two protective members existing between the gears 15 and 16 during bending, and the frictional force applied to the film catalyst is reduced. In addition, since a gap is formed between the two protective materials, the apparent compression rate increases, which is preferable in that the stress applied to the film-like catalyst during bending can be reduced. As shown in FIG. 1, the protective material 11 sent from the delivery roll 3 is changed in the delivery direction in the middle by using the support roll 4. When the catalyst layer is formed only on one surface of the long film catalyst 10, only the protective material 11 in contact with the catalyst layer may be sent out, or both protective materials 1 1 may be sent out. The delivery speed of delivery roll 1 and delivery rolls 2 and 3 are the same, or delivery roll 1 is faster. For example, it can be in the range of 0.5 to 5 O mZm in. The protective material 11 has the same width as the long film catalyst 10 or a slightly larger width, and the thickness (t,) of the long film catalyst 10 And the total thickness of the protective material 1 1 (t ₂ ) t ₂ t! 4 to 20 is preferable, and 4 to 12 is more preferable. The thickness (t,) is the total thickness of the catalyst layer (when there are catalyst layers on both sides of the support, the support thickness, the total thickness of one catalyst layer and the other catalyst layer). Thickness (t ₂ ) is the total thickness of the protective material used in the bending process (if there are catalyst layers on both sides of the support, this is the total thickness of the two protective materials, and two more on each side of the support In the case of bending, the total thickness of the four protective materials). The protective material 11 has a compressibility measured by the method described in the examples of 40 to 95%, preferably 50 to 95%, more preferably 70 to 95%. It is. By setting the compression ratio within the above range, it is possible to disperse the stress received by the catalyst layer from the gears by compressing the protective material 11, and the catalyst of the long film catalyst 10 during bending The layer is damaged and wrinkles are prevented and the catalyst is prevented from falling off. In addition, even when wrinkles occur in the protective material 1 1, the thickness of the protective material 1 1 changes substantially thin by compression in the space where the gears mesh with each other. Layer damage is inhibited. The protective material 11 preferably has a dynamic friction coefficient of 0.05 to 0.25, more preferably 0.05 to 0.2, and still more preferably 0.1 to 0.2. By setting the dynamic friction coefficient within the above range, a long film-like shape can be obtained during bending. When force is applied while the catalyst 10 and the protective material 1 1 are in contact, the protective material 1 1 slides on the surface of the long film catalyst 10 (catalyst layer surface) and damages the catalyst layer. Giving is prevented. In other words, even if the compression rate is high, damage to the catalyst layer is expected when it is hardened by deformation, so it is preferable to use a protective material with a low coefficient of dynamic friction to reduce the direct impact on the catalyst layer. Is desirable. The protective material 11 preferably has a porosity of 50% or more, more preferably 80 to 98%, and still more preferably 90 to 98%. By setting the porosity to the above range, the protective material itself can be easily compressed and deformed. When bending using a gear with a protective material interposed, stress is applied in a state where a film catalyst is sandwiched between protective gears between the gear and the gear. At this time, when a protective material that easily compresses and deforms within the above range, for example, a nonwoven sheet made of an aggregate of fibers, a void structure exists between the fibers. When stress is applied, the protective material (nonwoven fabric sheet) is compressed and the distance between the fibers is reduced, so that the stress increase and local concentration on the film catalyst are alleviated. Can act. In other words, it is preferable that the protective material used in the present invention has voids from the viewpoint of exhibiting such an action. In a protective material made of an aggregate of fibers, if the porosity is too small, there are many places where the fibers and the fibers come into contact with each other and the fibers deform even though there are voids between the fibers. Since the protective material compresses and deforms while substantially reducing the voids, the effect of relieving the stress during bending does not appear. In general film materials such as polyethylene resin disclosed in JP 1 A 8— 1 4 1 3 9 3, this porosity is very small, and there is no effect of dispersing stress applied during shape processing. It will give damage. JP-A 8— 1 4 1 3 9 3 Although there are gaps between the cellulose fibers, the amount is small, and the fibers constituting the protective material do not deform or move, and the effect of reducing the stress while compressing the thickness of the protective material is effective. It does not appear. The protective material 11 is preferably made of a non-woven fabric, and the material of the non-woven fabric is not particularly limited. The protective material 11 is made of a single fiber material such as known PET, PE, PP, or contains two or more types of fiber materials. Or having a core-sheath structure can be used. The long film-like catalyst 10 is passed between two gears 15 and 16 that are arranged to face each other with the teeth sandwiched between the protective materials 1 1 from both sides. . At this time, one protective material 11 is positioned between each of the two gears 15 and 16 and the long film catalyst 10.

The two gears 15 and 16 can be made of metal such as iron or stainless steel. When gears 15 and 16 are used in this way, bending work is less than when using gears with synthetic resin teeth, such as JP-A 8 _ 1 4 1 3 9 3. In addition to being easy and having excellent wear resistance, it is possible to extend the service life of the gear and to bend the gear while heating it. For example, a spur gear can be used as the gears 15 and 16, and the circular pitch (the value obtained by dividing the circumferential length of the gear pitch circle by the number of teeth) is 2 to 20 mm. It is possible to process with l ~ 20 mm. Thus, when the long film catalyst 10 passes between the two gears 15, 16, a long film catalyst 10 ′ processed into a wave shape is obtained. The long film-like catalyst 10 0 'processed into a wave shape is an extrusion action by two gears 15 and 16 The two protective members 1 1 are pushed out by the take-up rolls 2 'and 3', respectively. In addition, when bending a film catalyst (for example, square) for each sheet, for example, a method of bending by inserting a square film catalyst one by one between the two gears 15 and 16, sending out It is possible to apply a method in which a rectangular film catalyst is placed on the protective material 11 sent from the roll 2 or is temporarily placed and temporarily bent and placed and bent. In this method, the cutting process is not necessary. In this bending process, since the protective material 11 having a predetermined compression ratio is interposed between the long film catalyst 10 and the two gears 15 and 16, the gears 15 and 16. Even when a stronger force is applied, the catalyst layer of the long film catalyst 10 is prevented from being damaged and bent into a desired shape. The relationship between the distance (T) (see FIG. 2) between the two gears 15 and 16 that rub against each other, and the t ₁ and t ₂ is t 1 <T t + t ₂ . By having the above relationship, the film-like catalyst is held in close contact with the protective material between the two gears, and the protective material is compressed so that the film-like catalyst is sent in good condition along the shape of the gear. be able to. Therefore, the bending workability due to the shape imparting is improved, and the catalyst layer of the long film catalyst 10 is less likely to be damaged. Here, T is the inter-gear distance when the convex portion and concave portion of the two gears are held together and the distance between the two gears is reduced to the shortest distance as the zero reference. The long film catalyst 1 0 'processed into a wave shape in the previous process has the desired shape and After being cut into large sizes, for example, as shown in FIG. 3, it can be used as a catalyst assembly 20 in which a plurality of sheets are combined.

(2) Second Manufacturing Method Next, a manufacturing method according to an embodiment different from the first manufacturing method will be described. The manufacturing method of this embodiment is a method of pressing one by one. The film-like catalyst can be produced in the same manner as in the first production method, and can be prepared in advance in a desired shape and size. Therefore, a long film can be used in the first production method. There is no need for a post-process cutting step as in the case of using a catalyst. In the bending process, two plate-shaped bending tools placed opposite each other are used. The two plate-shaped bending tools are made of metal, an upper bending tool having a corrugated tooth formed on a flat plate, and a corrugated concave portion and a convex portion of the upper bending tool on the flat plate. It consists of a lower bending tool having convex and concave corrugated teeth. First, place a protective material on the corrugated teeth of the lower bending tool, place a film-shaped catalyst of the desired shape (having a catalyst layer on both sides or one side), and then place it on it. Put protective material. Next, with the upper bending tool, the film catalyst is pressed through the protective material to obtain a film catalyst processed into a wave shape. It is also possible to apply a method of pressing by placing two bending tools on the left and right. Since the protective material is the same as that of the first manufacturing method described above, the catalyst layer of the film-like catalyst is prevented from being damaged during the bending process. The film-like catalyst obtained by the production method of this step can be used depending on the type of the catalyst. Although it can be used as a catalyst for organic synthesis reactions, it can be applied to gas phase, liquid phase, and liquid reaction system. For example, oxidation of olefin, oxidation of alcohol, isomerism of olefin , Isomerization of aromatics, carbonylation, hydrogenation of ester, preferably dehydrogenation reaction, hydrogenation reaction. In particular, the combination of copper-nickel-ruthenium ternary powder catalyst and phenol resin as binder is used in combination with alcohols with dehydrogenation and hydrogenation reactions and primary or secondary amines to tertiary. Suitable for reactions for producing amines. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a conceptual diagram for explaining a production method of the present invention. FIG. 2 is a partially enlarged view for explaining the gear spacing shown in FIG. FIG. 3 is a perspective view of a catalyst assembly using a film catalyst obtained by the production method of the present invention. In the figure, there are a 10 long film catalyst, a film catalyst processed into a 10 'wave shape, 1 1 protective material, and 15 and 16 gears. Examples Although the present invention has been described based on the preferred embodiments, the present invention is not limited to the above embodiments. The following examples describe the practice of the present invention. The examples are illustrative of the invention and are not intended to limit the invention.

(1) Compression rate

Based on the method described in “Standardization and Analysis of Texture Evaluation”, Second Edition, Japan Textile Opportunity Association, Texture Measurement and Standardization Research Committee, issued July 10, 1980 It was measured. The measurement was performed using a product name KESFB 3-AUTO-A manufactured by Kato Tech Co., Ltd. as a measuring machine. A 20 cm x 20 cm test piece was prepared and attached to the test table of the measuring device. The specimen was compressed between copper plates with a 2 cm ² circular surface. The compression speed was 20 // m / sec and the maximum compression load was 59 kPa. The compression rate was calculated from the following formula. Compression rate (%) = (T. One T _m ) / T. x 1 00

(T. is the thickness of the specimen at a load of 49 Pa, and T _D is the thickness to the test at a maximum load of 59 kPa).

(2) Coefficient of dynamic friction (M I U)

Based on the method described in "Standardization and analysis of texture evaluation", 2nd edition, Japan Textile Opportunity Association, Texture Measurement and Standardization Research Committee, issued July 10, 1980 did. Measurement was performed using a trade name KE S F B 4—AUTO—A manufactured by Kato Tech Co., Ltd. as a measuring machine.

A 20 cm X 20 cm test piece was prepared and attached to the test table of the measuring device. The contact surface of the contact was pressed against the specimen with a force of 49 cN, and the specimen was moved 2 cm horizontally at a constant speed of 0.1 cmZsec. The specimen was given a uniaxial tension of 19.6 c NZcm. The contact is made of 20 piano wires of 0.5 hard diameter, arranged in a U-shape with a width of 1 Omm, and the contact surface is pressed against the test piece with a force of 49 c N by the weight. Since the value of (Friction coefficient) expressed by the following equation (i) changes during the movement of the surface of the test piece, the friction coefficient (MIU) is obtained by Equation (ii). = F p (i)

(F indicates frictional force [N], P indicates contact load [N])

MIU = (1 / Lma x) ^LDax / dL (ii) (L is the distance that the contact moves on the surface of the specimen, and Lmax is the maximum movement distance (= 2 CDI)).

(3) Thickness The thickness of the protective material was measured by a method in accordance with JIS L 1096. The probe diameter was 25.2 mm, the load was 0.343 N, and the measurement pressure was 0.7 kPa.

(4) Porosity When the thickness of the protective material is te (dragon) and the basic weight of the protective material is Bw (g / m ² ), the apparent density of the protective material PL is pL = Bw / te · 10 ' ³ (g / cm ³ ). Using AccuPic II I 340 (manufactured by Shimadzu Corporation), put a protective material in a stainless steel cell with an inner diameter of 1 8. δ mm, a length of 39.5 mm, and a capacity of 10 cm ³ The volume of the material is measured by the change in pressure of the helium, and the density of the protective material (0 r is calculated from the obtained volume and the weight of the sample. From the two obtained densities, the porosity of the protective material Rv (%) Is obtained from the following equation.

Rv = (1-pL / pr) X100 (%) Examples and Comparative Examples Production Example 1 (Production of Powdered Catalyst) Made of a copper / nickel / ruthenium ternary catalytic active material supported on a synthetic zeolite A powdered catalyst was prepared as follows. Synthetic zeolite (average particle size 6 m) was charged into a 1 L flask, and then copper nitrate, nickel nitrate, and ruthenium chloride were added at the molar ratio of each metal atom to Cu: Ni: A solution dissolved in water so that Ru = 4: 1: 0. 0 1 was added, and the temperature was raised while stirring. At 90, a 10% by mass aqueous sodium carbonate solution was gradually added dropwise while controlling the pH to 9-10. After aging for 1 hour, the precipitate was filtered, washed with water, dried at 80 ° for 10 hours, and calcined at 60 ° for 3 hours to obtain a powdered catalyst. In the obtained powdered catalyst, the proportion of metal oxide was 50% by mass, and the proportion of synthetic zeolite was 50% by mass.

(Manufacture of film catalyst) MIBK as solvent, phenol resin as binder (PR 1980 manufactured by Sumitomo Bakelite), powdered catalyst prepared in Production Example 1 in this order, placed in a 250 ml wide-mouth polyethylene bottle. It was. The mixing ratio is such that the non-volatile content of the phenol resin is 25 parts by mass with respect to 75 parts by mass (65 g) of the powdered catalyst, and the MIBK content is such that the solid content of the compound is 60% by mass. did. Furthermore, as a dispersion medium, a glass piece having a diameter of 1 mm (apparent volume of 65 ml) was placed in a wide-mouth polyethylene bottle. A wide-mouth polyethylene bottle was set in a paint shaker and mixed and dispersed for 30 minutes to obtain a coating composition. Using a long copper foil (thickness 40 m, weighing 3 10 gZm ² ) as a support, the coating composition was applied to both sides of the copper foil with a comma coater. In the drying furnace attached to the coating machine, treatment was carried out at 100 ° C. for 120 seconds, and then a film catalyst was obtained. The thickness of the catalyst layer was 50 m on one side, and the total thickness combined with the copper foil was 140 m. The catalyst layer had a supported amount of 63 g / m ² per side, and the supported amount of the powdery catalyst was 47 g / nre per side.

(Bending of film catalyst) The following materials were used as protective materials, and a film-like catalyst processed into a corrugated plate was manufactured using the apparatus shown in FIG. 1 and under the conditions shown in Table 1. The feed rate was ZiL iniii. The following tests were performed on the obtained film-like catalyst processed into a corrugated plate shape. The gears 15 and 16 used in the process were of the same shape, with a circle pitch of 4 mm and tooth depth of 2.5 mm. The results are shown in Table 1. Protective material 1: Nonwoven fabric made of PE (sheath) ZP ET (core) (basis weight 20 g / m ² ) made by melt-blowing method Protective material 2: Spunbond non-woven fabric Ecule 3151A (basis weight 15 gZm ² ) protection manufactured by Toyobo Material 3: Mitsui Chemicals spunbond nonwoven fabric Syntex PS104 (basis weight 20gZm ² ) Protective material 4: Spunbond nonwoven fabric Elves S1003WDO (basis weight lOOgZm ² ) Protective material 5: 100% cotton woven fabric ( Basis weight 144§ 111 ² ) Protective material 6: Toyobo spunbond nonwoven fabric ECLURE 3A01A (basis weight lOOgZm ² ) Protective material 7: Mitsui Chemicals spunbond nonwoven fabric Syntex PS120 (basis weight lOOgZm ² ) Protective material 8: Japan Paper-made PPC paper recycled cut plate 100N (basis weight 6 8gZm ² ) Protective material 9: Nonwoven fabric protective material made of PE (sheath) ZP ET (core) (basis weight 1 5gZm ² ) made by melt blow method 10 : PE (sheath) and ZP ET (core) made by the spunbond method (tsubo A non-woven fabric with an amount of 70 gZm ² ) treated with fluorine. Protective material 1 1: Pile sheet made of PTFE fiber (raised height 2 thighs, basis weight 5 10g / m ² ) Protective material 1 2: Twill weave fabric made of PTFE fiber (Toyoflon manufactured by Toray Industries, Inc.) 466g / m ² ) Protective material 1 3: Silicone rubber sheet (basis weight 654g / m ² , thickness 0.55mm) Protective material 14: PET film (basis weight 45g / m ² , thickness 0.03mm)

(Manufacturing condition evaluation test) The evaluation is as follows. <Processing test (1)> The surface of the film-like catalyst processed into a corrugated sheet and the surface of the catalyst material before processing are visually observed. <Processing test (2)> A comparative observation of the surface of the film catalyst when the protective material is processed into a corrugated sheet with wrinkles generated and the surface of the catalyst material before processing. These were evaluated according to the following criteria. In addition, the situation during <Processing Test (1)> was evaluated for running conditions.

A: <Processing test (1)> No change on the catalyst layer surface

<Processing test (2)> No change on the catalyst layer surface

◯: Gug processing test (1)> No change on the catalyst layer surface

<Processing test (2)> There is wrinkle transfer on the surface of the catalyst layer, but there is no peeling (film removal)

X: <Processing test (1)> Wrinkle transfer is observed on the surface of the catalyst layer, but there is no peeling (film removal)

Machining test (2)> No damage (peeling) occurs on the catalyst layer surface XX: <Processing test (1)> Damage (peeling) occurs on the catalyst layer surface <Processing test (2)> Evaluation of running condition where damage (peeling) occurs on catalyst layer surface> ○: Running condition of protective material and film catalyst is stable

△: Traveling of the protective material or film-like catalyst is slightly disturbed and slight meandering occurs: The protective material or film-like catalyst runs meandering and the running state is unstable

The thickness (ti) of the film catalyst is the total thickness of the support thickness plus both S catalysts.

The gears 15 and 16 used in the machining were of the same shape, and those with a circular pitch of 4 mm and tooth depth of 2.5 mm were used.

Claims

The scope of the claims

1. A method for producing a film-like catalyst, comprising: forming a catalyst layer on one or both sides of a support and performing a step of producing a film-like catalyst; and performing a step of bending the film-like catalyst, In the bending process, as the bending tool, two gears disposed so as to face each other are used so that the compression ratio is 40 between the catalyst layer of the film catalyst and the two gears. A method for producing a film-like catalyst, wherein bending is performed with 5 to 5% of a protective material interposed.

2. The is the ratio t ₂ Roh t! Is 4-2 0 the film catalyst with a thickness (t and the total thickness of the protective material (t _2), intervals defined in以卞of the two gears ( The method for producing a film-like catalyst according to claim 1, wherein the relationship between T) and tt ₂ is t ₁ <T <tt _2. However, T is a combination of a convex portion and a concave portion of two gears. The distance between the gears when the distance between the two gears is as close as possible to the shortest distance.

3. A method for producing a film-like catalyst, comprising forming a catalyst layer on one or both sides of a support and performing a step of producing a film-like catalyst, followed by a step of bending the film-like catalyst by pressing. The bending tool includes two upper and lower plate-shaped bending tools, and the two plate-shaped bending tools have corrugated teeth on a flat plate, each corrugated When the pressing is performed by the two upper and lower plate-shaped bending tools, the film catalyst catalyst layer and the bending additive are disposed so that the concave and convex portions of the teeth overlap. A method for producing a film-like catalyst, comprising bending a protective material having a compression ratio of 40 to 95% between the tool and the tool.

4. The method for producing a film catalyst according to any one of claims 1 to 3, wherein the protective material has a coefficient of dynamic friction of 0.05 to 0.25.

5. The method for producing a film-like catalyst according to any one of claims 1 to 4, wherein the protective material is a nonwoven fabric.